Method of adjustably mounting a fence rail to a fence post

ABSTRACT

A method of mounting a rail to a fence post including the steps of securing a fence rail mounting clip that includes a rail connector and a bracket to a side wall of a vertical fence post, determining a desired angle at which to mount the fence rail onto the fence post, moving the rail connector along an outer wall of the bracket so as to align an aperture in a rear wall of the rail connector with one of a plurality of angle-indicating characters disposed on the outer wall of the bracket, securing the rear wall and the outer wall together, and inserting a rail into a rail receiving receptacle on the rail connector.

CROSS-REFERENCE TO RELATED CASES

This is a Divisional of U.S. application Ser. No. 11/590,198, filed Oct.31, 2006, which is a continuation of U.S. application Ser. No.11/191,124, filed Jul. 27, 2005, now U.S. Pat. No. 7,147,212, which is acontinuation of U.S. application Ser. No. 10/246,285, filed Sep. 18,2002, now U.S. Pat. No. 6,986,505; which is a Continuation-in-Part ofU.S. application Ser. No. 10/056,719, filed Jan. 24, 2002, now U.S. Pat.No. 6,698,726; the entire disclosures of which are incorporated hereinby reference.

BACKGROUND OF THE INVENTION

1. Technical Field

This invention generally relates to the installation of fencing systems.More particularly, the invention relates to a method of fastening fencerails to vertical fence posts. Specifically, the invention relates to amethod of securing a fence rail to a fence post that includes installinga rail mounting clip, having a rail connector and a bracket, onto thevertical post, sliding the rail connector on an outer wall of thebracket to align an aperture in the rear wall of the connector with acharacter marked on the outer wall, securing the connector and brackettogether, and inserting a rail into a rail receiving receptacle on theconnector.

2. Background Information

It has recently become more common to use either vinyl or plasticproducts for constructing fences for yards or decks and for railings ondeck staircases. While vinyl fencing is aesthetically pleasing and easyto maintain, it poses somewhat of a problem for the contractor who mustconnect the various components together. It is difficult to connect thefence rails to the vertically extending fence posts. It is even moreproblematic if the rail must be secured to the post at an angle, as isrequired during construction of a staircase, or if a fence is beingbuilt over undulating terrain.

There is therefore a need for an improved rail clip for attachinghorizontal or angled fence rails to vertical fence posts and to a methodof using the same.

SUMMARY OF THE INVENTION

The present invention comprises a method of mounting a rail to a fencepost and includes the steps of securing a fence rail mounting clip,having a rail connector and a bracket, to a side wall of a verticalfence post, determining a desired angle at which to mount the fence railonto the fence post, moving the rail connector along an outer wall ofthe bracket so as to align an aperture in a rear wall of the railconnector with one of a plurality of angle-indicating charactersdisposed on the outer wall of the bracket, securing the rear wall andthe outer wall together, and inserting a rail into a rail receivingreceptacle on the rail connector.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention, illustrative of the bestmode in which applicant has contemplated applying the principles, areset forth in the following description and are shown in the drawings andare particularly and distinctly pointed out and set forth in theappended claims.

FIG. 1 is a partial side view of a staircase and deck utilizing thepresent invention;

FIG. 2 is a magnified view of the circled area of the rail clip fromFIG. 1;

FIG. 3 is a perspective view of the rail clip in accordance with thepresent invention;

FIG. 4 is an exploded perspective view of the rail clip;

FIG. 5 is a front view of the bracket of the rail clip;

FIG. 6 is a front view of the cover of the rail clip;

FIG. 7 is a front view of the rail connector of the rail clip;

FIG. 8 is a rear view of the rail connector of the rail clip;

FIG. 9 is a side view of the rail connector through line 9-9 of FIG. 7;

FIG. 10 is a front view of the base;

FIG. 11 is a side view of the base;

FIG. 12 is a rear view of the base;

FIG. 13 is a rear view of the bracket beginning to engage the base;

FIG. 14 is a rear view of the bracket partially engaged with the base;

FIG. 15 is a rear view of the bracket fully engaged with the base;

FIG. 16 is a cross-sectional side view of the rail clip positionedagainst the post;

FIG. 17 is a cross-sectional side view of the rail clip attached to thepost;

FIG. 18 is a cross-sectional bottom view of the rail clip attached tothe post through line 18-18 of FIG. 17;

FIG. 19, is a cross-sectional side view of the rail clip attached to thepost with the angular connector disposed at an angle to the post;

FIG. 20 is a cross-sectional side view of a rail being inserted into therail connector of the rail clip;

FIG. 21 is a side view of a fence constructed for undulating terrain andutilizing the rail clip of the present invention;

FIG. 22 is a magnified side view of a second embodiment of the rail clipas shown in FIG. 1;

FIG. 23 is a front view of cover of the rail clip shown in FIG. 22;

FIG. 24 is a rear view of the cover of FIG. 23;

FIG. 25 is a side view of the cover of FIG. 23;

FIG. 26 is front view of the rail connector of FIG. 22;

FIG. 27 is a partial side view of the rail connector of FIG. 26;

FIG. 28 is a partial cross-sectional top view of the rail connector ofFIG. 26;

FIG. 29 is a cross-sectional side view of the rail clip of FIG. 22showing the rail connector secured to the cover;

FIG. 30 is a cross-sectional side view of the rail clip of FIG. 22showing the rail connector secured to the cover at a different angle;

FIG. 31 is a cross-sectional top view of the rail clip of FIG. 22showing the rail connector secured to the cover;

FIG. 32 is a plan view showing two second embodiment rail clipsconnected to a vertical post, the rail clips being mounted in such a waythat the rail connector slides horizontally with respect to the bracket;

FIG. 33 is front view of the cover of the third embodiment of the railclip;

FIG. 34 is a rear view of the cover of FIG. 33;

FIG. 35 a front view of the rail connector of the third embodiment of arail clip in accordance with the present invention;

FIG. 36 is a partial cross-sectional top view of the rail connector ofFIG. 35;

FIG. 37 is a partial cross-sectional side view of the rail connector ofFIG. 35;

FIG. 38 is a cross-sectional side view of the third embodiment of therail clip showing the rail connector secured to the cover;

FIG. 39 is a cross-sectional top view of the third embodiment of therail clip through line 39-39 of FIG. 38;

FIG. 40 is a side view of the third embodiment of the rail clip securedto a vertical post;

FIG. 41 is a plan view showing the third embodiment of the rail clipsecured a vertical post;

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 there is shown a staircase generally indicated bythe numeral 10 that has stairs 12, vertical posts 14, and fence rails16. Rails 16 are preferably molded from plastic or vinyl and are hollow.Posts 14 may be wooden rectangular shaped posts that extend upwardlyfrom the ground. Rails 16 may be connected to each other by a pluralityof cross-beams or balusters 18. Rail clips, generally indicated by thenumeral 20, connect rails 16 to posts 14.

Rail clip 20 is preferably a multi-piece component that is molded of aresilient plastic material. Rail clip 20 may include a base 28, bracket21 and a rail connector 26. Bracket 21 may be molded as a single unit(FIG. 22—shown as bracket 121) or, as is shown in FIGS. 3-4, may be madeup of a housing 22 and cover 24.

Base 28 is preferably rectangular with rounded corners and has a frontsurface 72 and a rear surface 74 (FIGS. 10-12). A plurality of circularholes 70 are formed through base 28, each hole 70 having an enlargedcounterbore formed in front surface 72 and forming a stepped shoulder71. First screws 30 extend through holes 70 into a pair of holes (notshown) drilled in post 14 and axially aligned with holes 70. Aperipheral outer edge 73 of base 28 is tapered inwardly from frontsurface 72 to rear surface 74 so that rear surface 74 is smaller thanfront surface 72. A lip 78 is formed in the region where front surface72 extends beyond rear surface 74. Smaller rear surface 74 abuts post 14when base 28 is mounted thereon.

Referring to FIGS. 4-7, housing or bracket 22 has a flat, generallyU-shaped rear wall 32 and semicircular side surfaces 34, 34′. As seenfrom FIG. 4, side walls 34, 34′ do not extend all the way to the top 31and bottom 33 of rear wall 32. Ledges 35, 35′ are formed between the top31 and bottom 33 of rear wall 32 and the perimeters 49 of side surfaces34, 34′. Rear wall 32 has an interior surface 37 and exterior surface 39and has a pair of spaced-apart legs 41 that form a generally U-shapedslot 36 therebetween. Slot 36 is adapted to slidably receive base 28,the periphery of slot 36 being complementary shaped to engage thetapered outer edge 73 of base 28. Slot 36 is wider proximate bottom 33of rear wall 32 and then narrows to form guides 76. Slot 36 then narrowsfurther to a generally rectangular shaped area sized to receive and holdbase 28. Shoulders 76 a are provided proximate the upper end of guides76 to engage with shoulders 73 a on base 28. When base 28 is engaged inslot 36 the interlocking of shoulders 73 a and 76 a prevent withdrawalof base 28 from slot 36.

Housing 22 further includes three connecting walls 38 a, 38 b, 38 c thatare disposed at spaced intervals along interior surface 37 of rear wall32. As seen from FIG. 18, walls 38 b and 38 c are generally H-shaped,defining a space 43 through which base 28 may slide. Connecting walls 38a, 38 b and 38 c connect side walls 34, 34′ to each other and to rearwall 32. Connecting walls 38 define a plurality of pin-receiving holes40. The region of the walls immediately surrounding holes 40 isreinforced. A number of spacers 42 are positioned on the interiorsurfaces 34 a, 34′a of side walls 34, 34′ so that when housing 22 andcover 24 are assembled together a small gap (not shown) exists betweeninterior side surfaces 34 a, 34′a and side walls 46, 46′ of cover 24.Additionally, a number of brackets 45 extend between interior surface 37of rear wall 32 and interior side walls 34 a, 34′a. Brackets 45 are usedto strengthen housing 22.

Referring to FIGS. 4 and 6, cover 24 has a convexly curved outer wall 44and two semicircular side walls 46, 46′ that preferably extend at rightangles from outer wall 44. The diameter of side walls 46, 46′ issomewhat greater than the length of rear wall 32 of housing 22. Sidewalls 46, 46′ therefore have a greater radius than that of side walls34, 34′ of housing 22. Additionally, the width of outer wall 44 isslightly less than the distance between interior faces 47, 47′ of sidewall 46 and side wall 46′. A rim 51 is therefore formed around thecircumference of outer wall 44. As a result, when cover 24 and housing22 are assembled together, a first groove 53 is formed between rim 51 ofcover 24 and the perimeter 49 of side surfaces 34, 34′. (If bracket 21is manufactured as a single unit (not shown) first groove 53 may beformed in the sides of the unit.) A number of connecting walls 48 may bedisposed at spaced intervals along outer wall 44. Connecting walls 48join walls 46, 46′ to each other and to outer wall 44. A number ofconnector pins 50 extend from the interior face 55 of outer wall 44.Pins 50 are disposed a spaced distance apart from each other and thepositions of pins 50 correspond to the positions of pin-receiving holes40 of housing 22. Side walls 46, 46′ are partially cut away proximatetheir mid-section (FIG. 4) and walls 46, 46′ define a plurality of slits57. Slits 57 are positioned adjacent pins 50. When cover 24 engageshousing 22, slits 57 receive connecting walls 38 a, 38 b, 38 c ofhousing 22 therein so that pin-receiving holes 40 are located in thecorrect position to receive pins 50. When connecting walls 38 areengaged in slits 57 they also assist in keeping housing 22 and cover 24joined together and aid in preventing relative motion between cover 24and housing 22.

Inasmuch as pins 50 are adapted to interlock with pin-receiving holes 40and the connecting walls 38 a, 38 b and 38 c are adapted to be receivedinto slits 57 and thereby secure housing 22 to cover 24, it will beobvious to those skilled in the art that these components may bemanufactured on either of the housing 22 and cover 24, providing thecomplementary component is located on the other of housing 22 and cover24.

Referring to FIG. 7, rail connector 26 has an upper wall 52, lower wall54 parallel and spaced apart, side walls 56, 56′ and concavely curvedrear wall 58. Upper wall 52, lower wall 54 and side walls 56 form a railreceiving receptacle 66 into which an end of rail 16 may be inserted.Rear wall 58 partially projects into the rail receiving receptacle 66.The back edge 64, 64′ of side walls 56, 56′ is also concave in shape.Both rear wall 58 and side walls 56, 56′ are configured so that theircurvature is complementary shaped to the curvature of outer wall 44 ofcover 24. Rear wall 58 defines a plurality of holes 60 for receivingscrews 62 for securing rail connector 26 to cover 24. As seen from FIG.9, side walls 56, 56′ extend a short distance beyond rear wall 58 sothat a lip 78 is formed is formed between back edge 64, 64′ and rearwall 58. A ridge or boss 63 may be formed proximate back edge 64, 64′ ofeach side wall 56, 56′. Ridge 63 runs along back edge 64, 64′. A secondgroove 104 is formed between ridge 63 and rear wall 58. While secondgroove 104 is shown as formed between ridge 63 and rear wall 58, it maybe cut into lip 78. Ridge 63 is adapted to engage in first groove 53 andallows rail connector 26 to slide along cover 24. The sliding engagementof rail connector 26 and cover 24 allows the user to position the railreceiving receptacle 66 at any one of a range of positions along outerwall 44 of cover 24. When a rail 16 is received within rail receivingreceptacle 66, the rail 16 is disposed at a particular angle relative tobracket 21. As the position of rail connector 26 is changed by slidingit along first groove 53, the angle at which a rail 16 would be heldrelative to bracket 21 is changed. In this manner, the correct angle forattachment of rail 16 may be obtained. When the appropriate angle isdetermined by the installer, a drill bit (not shown) is inserted throughholes 60. Holes 84 are then drilled into outer wall 44 of cover 24.Second screws 62 are then inserted through holes 60 and 84 to securerail connector 26 to cover 24. Side walls 56, 56′ have an interior face61 and an exterior face 65 and a plurality of tabs 68 are disposed oninterior face 61. Tabs 68 prevent an end 96 of rail 16 from contactingrear wall 58 of rail connector 26. While tabs 68 are shown on side walls56, 56′, they may instead be positioned on interior faces (not shown) ofupper wall 52 and/or lower wall 54 or may be positioned on all of theside walls 56, 56′, upper wall 52 and lower wall 54.

Rail clip 20 is used in the following manner.

Referring to FIG. 4, when the user wishes to attach rail 16 to post 14,the location of base 28 is marked on post 14. Rear surface 74 of base 28is then placed against post 14. The position of holes 70 is marked ontopost 14 and the installer drills holes (not shown) into post 14 in themarked positions. Base 28 is then repositioned onto post 14 and firstscrews 30 are inserted through holes 70 and into post 14. Screws 30 arescrewed into post 14 until their heads rest on shoulder 71. It is ofcourse possible to secure base 28 to post 14 by other suitable securingmeans such as nuts and bolts or rivets.

Rail connector 26 is then attached to cover 24 by sliding one of firstend 96 or second end 98 of rail connector 26 onto one of first end 100or second end 102 of cover 24. This is accomplished by inserting rim 51into the second groove 104. Rail connector 26 is slidingly movedrelative to cover 24 until the two components are interlinked together.

The cover/rail connector combination 24/26 is then connected to housing22 in the following manner. Slits 57 are aligned with connecting walls38 a, 38 b and 38 c. Cover/rail connector combination 24/26 and housing22 are then pushed toward each other so that pins 50 engage inpin-receiving holes 40. As the cover/rail connector 24/26 and housing 22move toward each other, ridge 63 is captured within first groove 53.Cover/rail connector 24/26 and housing 22 are pushed together until pins50 lock in pin-receiving holes 40.

Referring to FIGS. 13-15, bottom end 33 of the housing/cover/railconnector combination 22/24/26 is brought into the vicinity of the topend 86 of base 28. Housing/cover/rail connector 22/24/26 is moveddownwardly toward upper end 86 of base and is maneuvered in such amanner that upper end 86 of base enters the widest section 88 of slot36. As combination 22/24/26 continues to move downwardly in thedirection of arrow “A” in FIG. 14, top end 86 of base 28 moves betweenguides 76 and into the narrower portion of slot 36. In this position,the edges 80 of legs 41 of rear wall 32 slide under lip 78 of base 28.As combination 22/24/26 continues to move downwardly in the direction of“A” until top end 86 of base 28 contacts upper end 92 of slot 36 (FIG.5). When base 28 is in this position, the housing/cover/rail connector22/24/26 is securely mounted onto post 14.

As will be obvious to those skilled in the art, it is possible toassemble rail clip 20 in any other manner. For example, base 28 may besecured to post 14, then housing 22 may be connected to base 28. Cover24 may then be interlocked with rail connector 26 and the combination ofcover 24 and rail connector 26 may then be snapped into place overhousing 22.

The installer then determines the appropriate angle required for rail 16relative to post 14. Rail connector 26 is slidably moved relative tocover 24 until the correct position is reached. The installer then markspoints to be drilled on outer wall 44 of cover 24 by inserting a markingimplement (not shown) through holes 60 in rear wall 58 of rail connector26. Holes 84 are then drilled into outer wall 44 and second screws 62are inserted through holes 60 and into holes 84.

An end 90 of rail 16 may then be inserted into rail receiving receptacle66 (FIG. 20). End 90 is moved into receptacle 66 until it engages tabs68.

As seen from FIGS. 1 and 21, rail clips 20 may be installed on twoadjacent posts 14 a, 14 b so that a rail 16 may be installed at theappropriate angle between the two posts 14 a, 14 b. The rail clips allowinstallers to install rails 16 at the correct angle even on fences thatare erected on undulating terrain 108.

A second embodiment of the invention is shown in FIGS. 22-31. In thisembodiment, the rail clip 120 includes a bracket 121 and a railconnector 126.

Referring to FIGS. 22-25, bracket 121 is a single molded piece made froma suitable material such as plastic or vinyl. Bracket 121 may begenerally semicircular in shape when viewed from the side. Bracket 121has an outer wall 123, a top wall 125 a, a bottom wall 125 b and sidewalls 127. Outer wall 123 includes a raised central area 129 disposedbetween two lower lateral areas 131. Lateral areas 131 define aplurality of slots 133 and apertures 135 through which screws 136 (FIG.32) may be inserted to secure bracket 121 to a vertical post 14. Lateralareas 131 are provided to allow for easy access to screws 136. Railconnector 126 is received onto raised central area 129 and consequentlyslots 133 and apertures 135 lay outside of rail connector 126 on lateralareas 131. The positioning of slots 133 and apertures on the lateralarea 131 on either side of rail connector 126 makes it easy to installrail clip 120 onto a vertical post 14 or to easily remove the same. Italso makes it easy to install rail clip 120 either vertically orhorizontally.

A plurality of characters or markings 137, 139 is preferably appliedonto or molded into outer wall 123 to aid in the installation of railclip 120. The characters may however be applied to any other suitablesurface of the device. These characters may be numbers, symbols, colorsor any other suitable markings and they are preferably marked ontoraised central area 129. For example, a plurality of first characters137 (such as numbers) may be applied to outer wall 123 to indicate theangle at which a fence rail 16 may be held by rail connector 126relative to bracket 121. Outer wall 123 may further include a pluralityof second characters 139 (such as dimples or holes) for accurateplacement of the tip of a drill bit (not shown). Second characters 139may be positioned so as to correspond with first characters 137, e.g.,dimple 139 a would correspond to character 137 a, dimple 139 b wouldcorrespond to first character 137 b to ensure correct placement of ascrew 143 to secure rail connector 126 to bracket 121. If an installerdesires to attach a rail 16 at the angle shown by first character 137 a,he would drill through the bracket 121 at the position marked by dimple139 a. While the preferred embodiment of this invention uses a dimplemolded into the outer wall 123 of bracket 121 to mark the spot fordrilling, any other suitable marking may be used, e.g., an “X” appliedto the outer surface in a suitable dye, or the use of a raised bump.Similarly, other suitable markings may be used to indicate angles atwhich a rail receiving receptacle 166 may be held relative to bracket121, e.g., bands of color with an explanatory key may be provided withthe rail clip's instructions. Other ways of marking the outer wall ofbracket 121 or rail connector 126 may be used without departing from thescope or intent of the present invention.

As seen from FIGS. 25 and 31, raised central area 129 further defines apair of lateral grooves 145. Grooves 145 may be open at least at a firstend 145 a to allow for engagement with rail connector 126. Grooves 145may, alternatively, be closed at a second end 145 b, to prevent railconnector 126 from sliding off bracket 121 or to limit the slidingmotion of rail connector 126 relative to bracket 121. Grooves 145 may bealigned either vertically or horizontally, thereby allowing for railconnector 126 to be moved relative to bracket 121 through either avertically oriented arc or a horizontally oriented arc.

Referring to FIGS. 26-28, rail connector 126 may be generallyrectangular in shape when viewed from the front. Rail connector 126 hasan upper wall 152, lower wall 154, side walls 156, 156′ and concavelycurved rear wall 158. Upper wall 152, lower wall 154 and side walls 156form a rail receiving receptacle 166 into which an end of rail 16 may beinserted. Rear wall 158 partially projects into the rail receivingreceptacle 166. Rear wall 158 is complementary shaped to engage raisedcentral area 129 of bracket 121. The back edge 164 of side walls 156,156′ may also be concave in shape. Both rear wall 158 and side walls156, 156′ are configured so that their curvature is complementary shapedto the curvature of outer wall 123 of bracket 121. Upper wall 152 mayextend farther rearward than lower wall 154 as shown in FIG. 27 andlower wall 154 may include a step 155 a. Upper wall 152 may include astep 155 b and rail 16 is adapted to abut steps 155 a, 155 b. Rear wall158 defines a hole 160 for receiving a screw 143 therethrough to secureconnector 126 to bracket 121. The location of hole 160 allows theinstaller to view second characters 139 on outer wall 123 of bracket121. Rear wall 158 further defines an aperture 162 through whichnumerical first characters 137 on outer wall 123 may be viewed.

As seen from FIG. 27, side walls 156, 156′ of rail connector 126 extenda short distance beyond rear wall 158 so that a lip 178 is formed isformed between back edge 164 and rear wall 158. A ridge or boss 163 maybe formed proximate back edge 164 of each side wall 156, 156′. Ridge 163runs generally parallel to back edge 164. A second groove 204 may beformed between ridge 163 and rear wall 158. Alternatively, second groove204 may be cut into lip 178. Ridge 163 is adapted to engage in firstgroove 145 of bracket 121 and to allow rail connector 126 to slide alongbracket 121. Rail connector 126 is connected to bracket 121 bypositioning one of upper wall 152 or lower wall 154 near to the open end145 a of groove 145 on bracket 121. A first end 163 a or 163 b of ridge163 is inserted into open end 145 a of groove 145. When ridge 163engages groove 145, back edges 164 engage lateral areas 131. Bracket 121and rail connector 126 may be moved relative to each other so that ridge163 slides along groove 145. The sliding engagement of rail connector126 and bracket 121 allows the user to position rail receivingreceptacle 166 at any one of a range of positions along outer wall 123of bracket 121. Side walls 156, 156′ have an interior surface 161 with aplurality of tabs 168 disposed thereon. Tabs 168 may alternatively, oradditionally, be positioned on interior surfaces 165 of upper and lowerwalls 152, 154. Tabs 168 prevent an end 96 of rail 16 from contactingrear wall 158 of rail connector 126 when it is inserted into receptacle166.

As the position of rail connector 126 is changed by sliding it alonglateral groove 145, the angle at which a rail 16 would be held relativeto bracket 121 is changed. In this manner, the correct angle forattachment of rail 16 may be obtained. If the installer knows the angleat which he needs to attach rail connector 126 to bracket 121, he maysimply align the appropriate first character 137 with aperture 162. Whenthe appropriate angle is determined by the installer, a drill bit (notshown) is inserted through hole 160 so that the tip (not shown) of thedrill bit engages in the appropriate dimple 139 on bracket 121. A hole184 is then drilled into outer wall 123 of bracket 121. A screw 143 isthen inserted through holes 160 and 184 in the direction of arrow A inFIG. 29 and is rotated so as to secure rail connector 126 to bracket121. The installer may, however, drill holes 184 at any position onraised central area 129.

Rail connector 126 and bracket 121 are configured in such a manner as toallow for installation of rails 16 at a variety of angles relative tovertical post 14. As seen from FIG. 22, bracket 121 may be secured tovertical post 14 in such a manner that rail 16 may be rotated about ahorizontal axis normal to post 14 or, as may be seen from FIG. 32,bracket 121 may be secured to post 14 in such a manner that rail 16 maybe rotated about a vertical axis parallel to post 14. Additionally,bracket 121 may be secured to post 14 in any other orientation that willallow the installer to position rail 16 at any desired angle relative topost 14.

The size of rail 16 most commonly used in fence construction is onereferred to as a two-by-four. In this type of rail the width of thepiece of wood or plastic is 1½ inches and its height is 3½ inches orvice versa. FIGS. 22, 23-31 illustrate a rail connector and bracketcombination 126/121 that allows for rail 16 to be oriented in such amanner that the width of the rail 16 (being 2 inches) lies proximateupper and lower walls 152, 154 of rail connector 126.

A third embodiment of the invention is shown in FIGS. 33-39. In thisembodiment, rail 16 may be oriented so that the width of the rail 16 is4 inches and its height is 2 inches. As seen from FIGS. 33-39, bracket221 is a single molded piece made from a suitable material such asplastic or vinyl. Bracket 221 is generally semicircular in shape whenviewed from the side. Bracket 221 has an outer wall 223, a top wall 225a, a bottom wall 225 b and side walls 227. Outer wall 223 may include araised central area 229 and lateral areas 231. Lateral areas 231 definea plurality of slots 233 and apertures 235. Screws 236 may be insertedthrough apertures 235 to secure bracket 221 to a vertical post 14. Aswith the second embodiment, a plurality of first characters 237 may bedisposed on outer wall 223 to indicate the angle at which a fence rail16 may be held by rail clip 220. A single group or series of firstcharacters 237 a or 237 b may be provided or both groups of firstcharacters 237 a and 237 b may be provided. First characters 237 a maybe inverted relative to the series of characters 239 so that no matterhow rail connector 226 is positioned relative to bracket 223, theinstaller can read off the desired angle of attachment. Outer wall 223further includes a plurality of second characters 237 for placement of atip of a drill bit (not shown). Second characters 237 are positioned soas to correspond with first characters 237. As with the previousembodiments, raised central area 229 defines a pair of lateral grooves245. Grooves 245 may be open at both ends (not shown) so that railconnector 226 may be engaged with bracket 221 from either end of groove245. Grooves 245 may be oriented either vertically or horizontally.Additionally, more than one set of first characters may be inscribedonto bracket 221 so that the installer can correctly orient railconnector 226 with respect to bracket 221 without turning rail clip 220around.

Rail connector 226 is shown in FIGS. 35-39. Rail connector 226 isgenerally rectangular in shape when viewed from the front. Railconnector includes an upper wall 252, a lower wall 254, side walls 256,256′ and concavely curved rear wall 258. Upper wall 252, lower wall 254and side walls 256 form a rail receiving receptacle 266 into which anend of rail 16 may be inserted. Rear wall 258 partially projects intothe rail receiving receptacle 266. Rear wall 258 is complementary shapedto engage raised central area 229 of bracket 221. The back edge 264 ofside walls 256, 256′ may also be concave in shape. Both rear wall 258and side walls 256,256′ are configured so that their curvature iscomplementary shaped to the curvature of outer wall 223 of bracket 221.Rear wall 258 defines a hole 260 for receiving a screw 243 therethroughto secure connector 226 to bracket 221. The location of hole 260 allowsthe installer to view second characters 239 on outer wall 223 of bracket221. Rear wall 258 further defines apertures 262 through which firstcharacters 237 on outer wall 223 may be viewed. While this embodimentshows that a plurality of holes 260 and apertures 262 are used to viewfirst and second characters 237, 239, one larger aperture (not shown)may be used to view both series of first characters and secondcharacters at the same time without departing from the scope of thisinvention. Alternatively, at least part of rail connector 126 may bemade out of a transparent material that allows the characters 137, 139on bracket 121 to be easily seen.

As seen from FIG. 37, side walls 256, 256′ of rail connector 226 extenda short distance beyond rear wall 258 so that a lip 278 is formed isformed between back edge 264 and rear wall 258. A ridge or boss 263 maybe formed proximate back edge 264 of each side wall 256, 256′. Ridge 263runs generally parallel to back edge 264. A second groove 304 may beformed between ridge 263 and rear wall 258. Alternatively, second groove304 may be cut into lip 278. Ridge 263 is adapted to engage in firstgroove 245 of bracket 221 and to allow rail connector 226 to slide alongbracket 221. Rail connector 226 is connected to bracket 221 bypositioning one of upper wall 252 or lower wall 254 near to an open end255 of groove 245 on bracket 221. A first or second 263 a or 263 b ofridge 263 is inserted into an open end 255 of groove 245. When ridge 263engages groove 245, back edges 264 engage lateral areas 231. Bracket 221and rail connector 226 may be moved relative to each other so that ridge263 slides along groove 245. The sliding engagement of rail connector226 and bracket 221 allows the user to position rail receivingreceptacle 266 at any one of a range of positions along outer wall 223of bracket 221. Side walls 256, 256′ have an interior surface 261 with aplurality of tabs 268 disposed thereon. Tabs 268 may alternatively, oradditionally, be positioned on interior surfaces 265 of upper and lowerwalls 252, 254. Tabs 268 prevent an end (not shown) of rail 16 fromcontacting rear wall 258 of rail connector 226 when it is inserted intoreceptacle 266.

There is therefore provided a method of assembling a fence rail to apair of fence posts comprising the following steps:

-   a. Mounting a first adjustable rail clip 20 a having a first rail    receiving area 26 a to a post 14 a;-   b. Mounting a second adjustable rail clip 20 b having a second rail    receiving area 26 b to a second post 14 b;-   c. Adjusting the first and second rail clips 20 a, 20 b such that    the first and second rail receiving areas 26 a, 26 b are axially    aligned;-   d. Placing a rail 16 in each of the first and second rail receiving    areas 26 a, 26 b in the aligned condition during mounting of at    least one of the first and second rail clips 20 a, 20 b.

The method of assembly may further include the step of adjusting eachrail clip 20 a, 20 b by sliding a movable rail connector 26 a, 26 b overa stationary bracket 21 a, 21 b.

The method of assembly may further include the step of mounting astationary bracket 21 a, 21 b to each of the posts 14 and adjusting arail connector 26 a, 26 b relative to each bracket 21 a, 21 b byrotating it arcuately about a radius formed on the bracket 21 a, 21 b.

The second and third embodiments of the invention are used in the samemanner as the first embodiment. However, installation may furtherinclude the step of adjusting the position of the rail connector 126 or226 relative to the bracket 121 or 221 so that numerical firstcharacters 137 or 237 are visible through holes 162 or 262. Theinstaller may then locate the correct drilling location by placing thetip of his drill bit (not shown) in a dimple 139 or 239, drilling therequired hole 160 or 260 and then using a screw to secure the railconnector and bracket together.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued.

Moreover, the description and illustration of the invention are anexample and the invention is not limited to the exact details shown ordescribed.

1. A method of mounting a rail to a fence post, said method comprisingthe steps of: securing a fence rail mounting clip, having a railconnector and a bracket, to a side wall of a vertical fence post;determining a desired angle at which to mount the fence rail onto thefence post; moving the rail connector along an outer wall of the bracketso as to align an aperture in a rear wall of the rail connector with oneof a plurality of angle-indicating characters disposed on the outer wallof the bracket; securing the rear wall and the outer wall together; andinserting a rail into a rail receiving receptacle on the rail connector.2. The method of mounting a rail as defined in claim 1, furthercomprising the step of securing at least one fastener through both ofthe rail and a peripheral wall of the rail receiving receptacle.
 3. Themethod as defined in claim 1, wherein the step of moving the railconnector further comprises sliding the rail connector along the outerwall.
 4. The method as defined in claim 1, wherein the step of moving arail connector on the mounting clip further includes the prior step ofinterlocking a lip on one of the rail connector and the bracket into agroove formed in the other of the rail connector and the bracket.
 5. Themethod as defined in claim 4, further comprising the step of sliding theinterlocked rail connector in an arc along the outer wall of thebracket.
 6. The method as defined in claim 1, wherein the step ofaligning the aperture further comprises aligning the aperture with oneof the plurality of angle-indicating characters selected from a firstgroup of characters consisting of numbers, colors, words, symbols anddimples which are provided on the outer wall of the bracket.
 7. Themethod as defined in claim 6, wherein the step of aligning the aperturefurther includes the step of aligning a second aperture in the rear wallof the rail connector with a second one of the plurality of charactersprovided on the outer wall of the bracket; and wherein the second one ofthe characters is selected from a second group of characters consistingof numbers, colors, words, symbols and dimples that are provided on theouter wall of the bracket a spaced distance from the first group ofcharacters.
 8. The method as defined in claim 7, wherein the step ofmoving the rail connector further includes moving the rail connector inone of a first and a second direction; where movement in the firstdirection is undertaken to align the first aperture with the first oneof the selected characters; and movement in the second direction isundertaken to align the second aperture with the second one of theselected characters.
 9. The method as defined in claim 1, wherein thestep of securing the fence rail mounting clip to the fence postincludes: fixedly securing a first portion of the bracket to the fencepost using one or more fasteners; and sliding a second portion of thebracket vertically over the first portion thereof to interlockinglyengage the first and second bracket portions together.
 10. The method asdefined in claim 9, wherein the step of securing the fence rail mountingclip to the fence post further includes the step of mounting the bracketonto the fence post so that the outer wall thereof is substantiallyparallel to a vertical axis of the fence post; whereby the movement ofthe rail connector on the outer wall is substantially parallel to thevertical axis.
 11. The method as defined in claim 9, wherein the step ofsecuring the fence rail mounting clip to the fence post further includesthe step of mounting the bracket onto the fence post so that the outerwall thereof is substantially perpendicular to a vertical axis of thefence post; whereby the movement of the rail connector on the outer wallis substantially perpendicular to the vertical axis.
 12. The method asdefined in claim 9, wherein the step of securing the fence rail mountingclip to the fence post further includes the step of mounting the bracketonto the fence post so that the outer wall thereof is oriented at anangle to a vertical axis of the fence post; whereby the movement of therail connector on the outer wall is substantially at the same angle tothe vertical axis.
 13. The method as defined in claim 1, wherein thestep of securing the rear wall and outer wall together comprises thesteps of inserting at least one fastener through both of the rear walland outer wall.